Installing Chain Case Lid

Installing chain case lid

Tools





Information

Component overview

Top chain case lid








Chain case lid, bottom








Tools and materials

Special tools








Installing top chain case lid

ATTENTION Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
^ Components must have reached at least 17°C throughout.
^ Components must not be too hot (distortion).
^ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.

Note: If both chain case lids were removed, install the bottom one first.

1. Check all sealing rings and replace if necessary.
2. Check sealing rings for the hydraulic valves of the camshaft adjusters and replace if necessary.





3. Prepare cylinder head gasket for installation of the chain case lid. To do this, apply silicone sealant 000.043.300.39 to the corners of the cylinder head gasket and cylinder head. Fill the bores of the cylinder head gasket with sealant -arrows-.
4. Apply a thin coat of sealant 000.043.300.39 evenly to the sealing faces (don't forget the contact surfaces for the cylinder head gasket).








5. Tighten all fastening screws M6 (6 M6 x 56 screws and 1 M6 x 20 screw) Tightening torque: 8 (6 ft-lb.) Nm Fastening screws and the M8 x 28 fastening screws -2- to the tightening torque Tightening torque: 23 (17 ft-lb.) Nm. Screw in chain tensioner with a new sealing ring -1-. Tightening torque: 40 (30 ft-lb.) Nm





6. Check sealing ring on water tube and replace if necessary. Then push the coolant temperature regulator housing on to the water tube -arrow-.





Note: Check sealing ring on coolant temperature regulator housing and replace if necessary.

7. Install coolant temperature regulator housing. To do this, position 2 M6 x 120 and 1 M6 x 23 fastening screws -3- and tighten to tightening torque Tightening torque: 8 (6 ft-lb.) Nm. Fit 3 M6 fastening screws on sheetmetal holder for run-on pump -1- and tighten Tightening torque: 8 (6 ft-lb.) Nm. Fit coolant hose and clamps -2-.








8. Fit the aluminum water tube by tightening the 2 M6 x 12 fastening screws. Tightening torque: 10 (7.5 ft-lb.) Nm
9. Lay wiring harness.
10. Connect cable plug of coolant temperature sensor to coolant temperature regulator housing -10-.








11. Fit valve for active carbon filter and coolant run-on pump to sheetmetal bracket and connect cable plug for active carbon filter valve -1- and cable plug for coolant run-on pump -2-.
12. Connect marked cable plugs to the appropriate camshaft hall senders.
13. Connect both cable plugs for the hydraulic valves for camshaft adjustment.

Installing bottom chain case lid

ATTENTION Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
^ Components must have reached at least 17°C throughout.
^ Components must not be too hot (distortion).
^ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.





1. Prepare cylinder head gasket for installation of the chain case lid. To do this, apply silicone sealant 000.043.300.39 to the corners of the cylinder head gasket and cylinder head. Fill the bores of the cylinder head gasket with sealant -arrows-.
2. Apply a thin coat of sealant 000.043.300.39 evenly to the sealing faces (don't forget the contact surfaces for the cylinder head gasket).








3. Position and tighten all fastening screws , to do this, tighten 2 M8 x 28 -1-, 14 M6 x 16, 2 M6 x 57 and 3 M6 x 18 (oil pan) -2- to tightening torque. Tightening torque: 10 (7.5 ft-lb.) Nm Tightening torque: 12 (9 ft-lb.) Nm Tightening torque: 25 (19 ft-lb.) Nm





4. Replace crankshaft sealing ring on flywheel side.

Replacing sealing rings for the hydraulic valves for camshaft adjustment

1. Remove top chain case lid.





2. Place top chain case lid on a level support. Make sure to leave sufficient space below the chain case lid for driving out the sealing ring. Drive out sealing ring using socket wrench insert 9714 and a plastic hammer.





3. Turn the top chain case lid over, fit the new sealing ring by hand and carefully drive it in flush using pressure sleeve T10174 and a plastic hammer.
4. Install top chain case lid.

Subsequent work for top chain case lid
1. Mount cylinder head cover.
2. Install engine.

Touching up bottom chain case lid
1. Install flywheel or drive plate.
2. Install transmission.